Clutch actuator unit and washing machine

ABSTRACT

An actuator to drive a clutch member provided in a washing machine is coupled to a sensor unit to constitute a clutch actuator unit. A first case of the actuator in which the drive mechanism is housed and a second case of the sensor unit in which a sensor is housed are coupled by a coupling unit provided outside the first case and outside the second case. The coupling unit is provided in an overlapping portion of a first protruding unit protruding from a first side surface of the first case, and a second protruding unit protruding from a second side surface of the second case.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the priority of patent Japan application serialno. 2019-079006, filed on Apr. 18, 2019, and Japan application serialno. 2019-235913, filed on Dec. 26, 2019. The entirety of theabove-mentioned patent application is hereby incorporated by referenceherein and made a part of this specification.

BACKGROUND Field of the Invention

The present invention relates to a clutch actuator unit and a washingmachine.

Description of the Related Documents

In a washing machine, a clutch device is provided at a position midwayof a driving force transmission path from a motor for the washingmachine to a washing tub, such that during washing, the clutch drivetransmits the rotational driving force to a pulsator withouttransmitting to the washing tub, and during spin-drying, the clutchdevice transmits the rotational driving force to the washing tub and thepulsator. The clutch device has an actuator for driving a clutch member,and the actuator has a case including a plurality of members and a drivemechanism housed inside the case (see Japanese Unexamined PatentApplication Publication No. 2014-68854).

A washing machine may be provided with a sensor for detecting therotation of the washing tub, and in this case, if a sensor unit formedby housing the sensor in a case and an actuator are coupled to form aclutch actuator unit, it becomes easy to assemble the washing machine.For example, if a part of the case of the sensor unit is sandwichedbetween a plurality of members constituting the case of the actuator,and both the cases are coupled, it is possible to couple the sensor unitand the actuator.

Because the actuator is arranged at a position downward of the washingtub, it is preferable that in the case of the actuator, a side surfaceof the case has a waterproof structure except for a location where anoutput member that drives the clutch member protrudes out. However, whenthe sensor unit and the actuator are coupled so that a part of the caseof the sensor unit is sandwiched between the plurality of membersconstituting the case of the actuator, there is a problem that thewaterproof property of the side surface of the case of the actuatortends to decline.

In view of the above problem, an object of the present invention is toprovide a clutch actuator unit and a washing machine by which it ispossible to couple a first case of the actuator and a second case of thesensor unit without causing a decline in the waterproof property of thefirst case and the second case.

SUMMARY

To solve the above problem, a clutch actuator unit according to at leastan embodiment of the present invention includes an actuator including adrive mechanism to drive a clutch member arranged in a driving forcetransmission path from a washing machine motor to a washing tub, and afirst case in which the drive mechanism is housed and a sensor unitincluding a sensor to detect rotation of the washing tub, and a secondcase in which the sensor is housed. In the clutch actuator unit, acoupling unit to couple the first case and the second case is providedoutside the first case and outside the second case.

According to at least an embodiment of the present invention, becausethe coupling unit to couple the first case of the actuator and thesecond case of the sensor unit is provided outside the first case andoutside the second case, it is possible to couple the first case of theactuator and the second case of the sensor unit without causing adecline in the waterproof property of the first case and the secondcase.

In at least an embodiment of the present invention, it is possible toadopt a mode in which the coupling unit is provided in an overlappingportion of a first protruding unit protruding from a first side surfacebeing a side surface of the first case, and a second protruding unitprotruding toward the first case from a second side surface being a sidesurface of the second case. According to the mode, it is possible toeasily provide the coupling unit between the first case and the secondcase outside the first case and outside the second case.

In at least an embodiment of the present invention, it is possible toadopt a mode in which in the first case, the first side surface isformed by a plurality of first members stacked in an up-down direction,and in the second case, the second side surface is formed by a pluralityof second members stacked in the up-down direction, the first protrudingunit is provided in any one of the plurality of first members, and thesecond protruding unit is provided in any one of the plurality of secondmembers.

In at least an embodiment of the present invention, it is possible toadopt a mode in which among the plurality of first members, the firstprotruding unit is provided in a first member arranged on one of anuppermost side and a lowermost side, and among the plurality of secondmembers, the second protruding unit is provided in a second memberarranged on the other of the uppermost side and the lowermost side so asto overlap the first protruding unit from the other side. According tothe mode, it is easy to realize a structure in which the firstprotruding unit and the second protruding unit overlap in the up-downdirection.

In at least an embodiment of the present invention, it is possible toadopt a mode in which in each of the first protruding unit and thesecond protruding unit, a hole is provided through which a fasteningmember to fix the first case and the second case to a washing machinepasses. According to the mode, it is possible to fix the first case andthe second case to the washing machine using the first protruding unitand the second protruding unit.

In at least an embodiment of the present invention, it is possible toadopt a mode in which in the first member provided with the firstprotruding unit and the second member provided with the secondprotruding unit, a hole is provided through which a fastening member tofix the first case and the second case to a washing machine passes, inan inner peripheral surface of the hole provided in the first member, oran inner peripheral surface of the hole provided in the second member, afastening member holding unit protruding radially inward is provided,and the fastening member is held in the fastening member holding unit.This allows the fastening member to be temporarily fixed to thefastening member holding unit in advance and shipped together with theclutch actuator unit. Therefore, in a step of fixing the clutch actuatorunit to the washing machine, it is not necessary to separately supply afastening member. Further, because it is possible to perform the fixingoperation to the washing machine from a state in which the fasteningmember is arranged in the fixing hole in advance, the fixing operationto the washing machine is easy.

In at least an embodiment of the present invention, it is possible toadopt a mode in which an inner peripheral surface of the fasteningmember holding unit is a positioning unit to come into contact with apositioning pin provided on a jig. By adopting the mode, it is alsopossible to use the fastening member holding unit as a positioning unitfor positioning with respect to the jig. Therefore, there is no need toseparately form a positioning unit, because of which it is possible tosimplify the configuration of the first member or the second member.

In at least an embodiment of the present invention, it is possible toadopt a mode in which the fastening member holding unit is formed on theentire circumference. By adopting the mode, the fastening member can beheld by the entire circumference.

In at least an embodiment of the present invention, it is possible toadopt a mode in which as compared to an end unit of the hole on a firstside, the fastening member holding unit is located on a second sideopposite to the first side, and as compared to an end unit of the holeon the second side, the fastening member holding unit is located on thefirst side. By adopting the mode, if the fastening member is temporarilyfixed to the fastening member holding unit, it is possible to preventthe leading end of the fastening member from projecting out from the endunit of the hole.

In at least an embodiment of the present invention, it is possible toadopt a mode in which the fastening member holding unit includes acontact surface facing the first side or the second side. By adoptingthe mode, it is possible to position the first case or the second casein the axial direction of the hole using the contact surface. Further,upon temporarily fixing of the fastening member, it is possible toprevent the leading end of the fastening member from projecting out fromthe hole by bringing the leading end surface of the fastening member incontact with the leading end surface of the positioning pin abuttingagainst the contact surface.

In at least an embodiment of the present invention, it is possible toadopt a mode in which among the plurality of first members, the twofirst members stacked in the up-down direction have a fitting structurein which side plates of the two first members overlap in both theup-down direction and the inner-outer direction, and among the pluralityof second members, the two second members stacked in the up-downdirection have a fitting structure in which side plates of the twosecond members overlap in both the up-down direction and the inner-outerdirection. According to the mode, it is possible to enhance thepreventive property between the two first members stacked in the up-downdirection, and the waterproof property between the two second membersstacked in the up-down direction.

In at least an embodiment of the present invention, it is possible toadopt a mode in which among the two first members, the side plate of thefirst member located on the upper side overlaps the side plate of thefirst member located on the lower side from the outside, and among thetwo second members, the side plate of the second member located on theupper side overlaps the side plate of the second member located on thelower side from the outside. According to the mode, it is possible toprevent the water that has dropped from above from entering the insideof the first case from between the two first members stacked in theup-down direction, and also to prevent the water from entering theinside of the first case and the second case from between the two secondmembers stacked in the up-down direction.

In at least an embodiment of the present invention, it is possible toadopt a mode in which the coupling unit includes an engagementprotruding unit formed on one of the first case and the second case, andan engagement hole that is provided on the other of the first case andthe second case and in which the engagement protruding unit is fitted.

A washing machine including the clutch actuator unit according to atleast an embodiment of the present invention includes the washingmachine motor, the washing tub, a pulsator arranged in the washing tub,and a driving force transmission mechanism to transmit a rotationaldriving force of the washing machine motor to the washing machine tuband the pulsator. In the washing machine, the clutch actuator unitdrives the clutch member to realize a connection state in which therotational driving force is transmitted to the washing tub and thepulsator, and a disconnection state in which the rotational drivingforce is transmitted to the pulsator and is not transmitted to thewashing tub.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments will now be described, by way of example only, withreference to the accompanying drawings which are meant to be exemplary,not limiting, and wherein like elements are numbered alike in severalFigures, in which:

FIG. 1 is a vertical cross-sectional view illustrating a schematicconfiguration of a washing machine to which at least an embodiment ofthe present invention is applied;

FIG. 2 is an explanatory diagram of a driving force transmissionmechanism and the like illustrated in FIG. 1;

FIG. 3 is a perspective view of a clutch device provided in the washingmachine illustrated in FIG. 1 as viewed obliquely from above;

FIG. 4 is a perspective view of the clutch device illustrated in FIG. 3as viewed obliquely from below;

FIG. 5 is a perspective view of a state where the actuator is fixed tothe support member illustrated in FIG. 2 as viewed from above;

FIG. 6 is a perspective view of the clutch actuator unit in which theactuator and the sensor unit illustrated in FIG. 2 and the like arecoupled to each other as viewed from the side opposite to the sensorunit;

FIG. 7 is a perspective view of a state where the actuator and thesensor unit are separated from the state illustrated in FIG. 6;

FIG. 8 is a perspective view of the clutch actuator unit illustrated inFIG. 6 as viewed from the sensor unit side;

FIG. 9 is a perspective view of a state where the actuator and thesensor unit are separated from the state illustrated in FIG. 8;

FIG. 10 is an exploded perspective view of a first case, a second case,and the like of the clutch actuator unit illustrated in FIG. 6;

FIG. 11 is an exploded perspective view of a drive mechanism, a sensor,and the like of the clutch actuator unit illustrated in FIG. 6;

FIG. 12 is a cross-sectional view illustrating a waterproof structure ofthe first case and the second case illustrated in FIG. 10 and the like;

FIG. 13 is a perspective view of the clutch actuator unit illustrated inFIG. 6 as viewed from below, and a cross-sectional view illustrating astate in which a fastening member is temporarily fixed to a cylindricalunit;

FIG. 14 is a perspective view of the clutch actuator unit and aninspection jig illustrated in FIG. 6; and

FIG. 15 is a cross-sectional view of a cylindrical unit and apositioning pin.

DETAILED DESCRIPTION

According to at least an embodiment of the present invention, becausethe coupling unit to couple the first case of the actuator and thesecond case of the sensor unit is provided outside the first case andoutside the second case, it is possible to couple the first case of theactuator and the second case of the sensor unit without causing adecline in the waterproof property of the first case and the secondcase.

An embodiment for carrying out the present invention will be describedwith reference to the drawings. It is noted that in FIG. 2, FIG. 3, andFIG. 4 referenced below, an actuator 7 is schematically illustrated as acuboid, and the actual appearance of the actuator 7 is illustrated inFIG. 6 and the like.

Entire Configuration

FIG. 1 is a vertical cross-sectional view illustrating a simplifiedconfiguration of a washing machine 1 to which at least an embodiment ofthe present invention is applied. In the washing machine 1 illustratedin FIG. 1, a cylindrical main body frame 2 has an opening unit 2 a fortaking out and putting in laundry such as clothes on an upper surface,and has an open lower surface. A bottomed cylindrical washing tub 3 ishoused inside the main body frame 2 with an opening unit 3 a facingupward. The washing tub 3 is suspended from the main body frame 2 via abuffer member (not illustrated), and is rotatable around the axis L0. Apulsator 4 is arranged on the bottom inside the washing tub 3.

A washing machine motor 5 is arranged below the washing tub 3. Therotational driving force of the washing machine motor 5 is transmittedto the washing tub 3 and the pulsator 4 via a driving force transmissionmechanism 6. The driving force transmission mechanism 6 includes aclutch device 10 that connects and disconnects the transmission of therotational driving force of the washing machine motor 5 to the washingtub 3 midway of a first driving force transmission path 1 a from thewashing machine motor 5 to the washing tub 3. A sensor for detecting arotation of the washing tub 3 is arranged below the washing tub 3, andthe configuration of the sensor will be described later. The clutchdevice 10 has a plate-shaped support member 19, and the clutch device 10is supported by the main body frame 2 via the support member 19. Thesupport member 19 is cup-shaped, as will be described later withreference to FIG. 5, but FIG. 1 and FIG. 2, which will be describedlater, illustrate only the bottom plate unit.

If the washing machine 1 operates in a state where clothes have beenloaded inside the washing tub 3, the washing water is supplied insidethe washing tub 3 via a water supply pipe (not illustrated). Thereafter,if the washing machine motor 5 is driven, the pulsator 4 rotates, andthe clothes in the washing tub 3 are washed. During the washingoperation, the clutch device 10 is in a disconnection state fordisconnecting the transmission of the rotational driving force of thewashing machine motor 5 to the washing tub 3. Therefore, the washing tub3 is stopped.

If the washing operation ends and the washing water is discharged fromthe washing tub 3, a spin-drying operation is performed. In thespin-drying operation, the washing machine motor 5 is driven in a statewhere the clutch device 10 is in a connection state for transmitting therotational driving force of the washing machine motor 5 to the washingtub 3. As a result, the pulsator 4 and the washing tub 3 rotateintegrally, and the clothes in the washing tub 3 are dried.

Driving Force Transmission Mechanism

FIG. 2 is an explanatory diagram of a driving force transmissionmechanism 6 and the like illustrated in FIG. 1, and (a) of FIG. 2 and(b) of FIG. 2 are respectively an exploded perspective view of the mainparts of the driving force transmission mechanism 6, and an explanatorydiagram of the support member 19. As illustrated in FIG. 1 and FIG. 2,the driving force transmission mechanism 6 includes a first rotatingbody 13 to which the rotational driving force of an output shaft 11 ofthe washing machine motor 5 is transmitted via an endless belt 12, arotary shaft 17 coaxially attached to the first rotating body 13, acoupling member 15 coaxially connected to a lower end portion of thewashing tub 3, and a second rotating body 20 coupled to the couplingmember 15. The first rotating body 13 has a disk shape, and is arrangedcoaxially with the washing tub 3 below the washing tub 3. The circularouter peripheral surface of the first rotating body 13 is a mountingsurface 13 a on which the endless belt 12 is mounted.

The first rotating body 13 is provided with tooth units 13 b arranged ina circumferential direction on an upper end surface. A lower end portionof the rotary shaft 17 is coupled to the first rotating body 13, and anupper end portion of the rotary shaft 17 is coupled to the pulsator 4through the bottom unit of the washing tub 3. Therefore, the rotationaldriving force of the washing machine motor 5 is transmitted to thepulsator 4 via the endless belt 12, the first rotating body 13, and therotary shaft 17. That is, a second driving force transmission path 1 bincluding the endless belt 12, the first rotating body 13, and therotary shaft 17 is formed between the washing machine motor 5 and thepulsator 4.

The rotary shaft 17 is arranged inside a cylindrical member 16. Thecylindrical member 16 and the rotary shaft 17 are not coupled to eachother, and the cylindrical member 16 is in a state of being relativelyrotatable with respect to the rotary shaft 17. The outer peripheral sideof the cylindrical member 16 is coupled to the coupling member 15, andthe cylindrical member 16 and the coupling member 15 rotate integrally.The coupling member 15 includes a large-diameter flange unit 15 acoupled to the washing tub 3, and a small-diameter cylindrical unit 15 bsmaller in diameter than the large-diameter flange unit 15 a, from thetop to bottom in the direction of the axis L0. The cylindrical member 16is inserted inside the small-diameter cylindrical unit 15 b, and thecylindrical member 16 is coupled to the small-diameter cylindrical unit15 b so as to rotate together with the coupling member 15. The secondrotating body 20 is coaxially coupled to the outer peripheral side ofthe lower portion of the small-diameter cylindrical unit 15 b.

While on one hand, a plurality of vertical grooves 26 a are formed onthe inner peripheral surface of the second rotating body 20, a pluralityof ridges 26 b constituting the vertical grooves 26 a and serrations 26are formed on the outer peripheral surface of the small-diametercylindrical unit 15 b. Therefore, as a result of the serrations 26, thesecond rotating body 20 is coupled in a state so as to be relativelymovable in the direction of the axis L0 with respect to the couplingmember 15, and be integrally rotatable with the coupling member 15.

Configuration of Clutch Device 10

FIG. 3 is a perspective view of the clutch device 10 provided in thewashing machine 1 illustrated in FIG. 1 as viewed obliquely from above,(a) of FIG. 3 and (b) of FIG. 3 are respectively a perspective view andan exploded perspective view of the entire clutch device 10. FIG. 4 is aperspective view of the clutch device 10 illustrated in FIG. 3 as viewedobliquely from below, (a) of FIG. 4 and (b) of FIG. 4 are respectively aperspective view and an exploded perspective view of the entire clutchdevice 10.

As illustrated in FIG. 3 and FIG. 4, the clutch device 10 includes thesecond rotating body 20 that can be engaged with the first rotating body13, a clutch member 40 for displacing the second rotating body 20, andthe actuator 7 that causes the clutch member 40 to move to-and-frobetween a connection position where the second rotating body 20 and thefirst rotating body 13 are mechanically connected, and a disconnectionposition where the mechanical connection between the second rotatingbody 20 and the first rotating body 13 is released. In the clutch device10, a compression coil spring 14 illustrated in FIG. 2 urges the clutchmember 40 downward via the second rotating body 20. The clutch member 40has an annular unit 41 and an engagement plate unit 42 protrudingradially outward from one location in the circumferential direction ofthe annular unit 41, and the actuator 7 causes the clutch member 40 toswing to-and-fro around an axis L0 passing through the center of theannular unit 41.

The clutch device 10 includes a cover 30 that houses the clutch member40 and the like, and the cover 30 has a lower cover 31 that covers theclutch member 40 and the like from below, and an upper cover 32 thatcovers the clutch member 40 and the like from above.

The lower cover 31 has a cylindrical first cover unit 311, and a secondcover unit 312 having a square tube shape and protruding radiallyoutward from the first cover unit 311. The upper cover 32 has an annularthird cover unit 321 overlapping the first cover unit 311 of the lowercover 31, and a fourth cover unit 322 having a square tube shape andprotruding radially outward from the third cover unit 321 to overlap thesecond cover unit 312 of the lower cover 31. The lower cover 31 and theupper cover 32 are arranged to overlap each other via the support member19, and an engagement hole of a plate unit 313 protruding upward fromthe lower cover 31 is engaged with an engagement protruding unit 323formed on the side surface of the upper cover 32 to perform coupling. Inthis state, the second rotating body 20 and the annular unit 41 of theclutch member 40 are arranged between the first cover unit 311 and thethird cover unit 321 so as to be rotatable around the axis L0.

The first cover unit 311 has an annular bottom plate unit 314, acylindrical first body unit 315 protruding upward from an outerperipheral edge of the bottom plate unit 314, and a cylindrical secondbody unit 317 connected to the first body unit 315 at an upper side. Thesecond body unit 317 has a larger diameter than the first body unit 315.For this reason, on the inner peripheral surface of the first cover unit311, an annular step unit 316 facing upward is formed between the firstbody unit 315 and the second body unit 317.

Configuration of Second Rotating Body 20

The second rotating body 20 has a cylindrical first body unit 21, anannular flange unit 27 the diameter of which expands at the upper endunit of the first body unit 21, a cylindrical second body unit 22protruding downward from the first body unit 21, and a third body unit23 protruding downward from an outer edge of the flange unit 27, and inthe third body unit 23, a slit 230 detected by a photo interrupter(sensor 83) described later with reference to FIG. 11 is formed.

The plurality of vertical grooves 26 a constituting the serrations 26are formed on an inner peripheral surface of the first body unit 21.Because the flange unit 27 has a larger diameter than the first bodyunit 21, a ring-shaped first step unit 24 facing downward is formedbetween the flange unit 27 and the first body unit 21 on the outerperipheral surface of the second rotating body 20. The first step unit24 overlaps the annular bottom plate unit 314 of the lower cover 31upward through the annular unit 41 of the clutch member 40. Moreover,because the second body unit 22 has a smaller diameter than the firstbody unit 21, a ring-shaped second step unit 25 facing downward isformed between the second body unit 22 and the first body unit 21 on theouter peripheral surface of the second rotating body 20.

The lower end unit of the second body unit 22 is exposed downward (onthe side where the first rotating body 13 is located) through a hole 314a formed in the bottom plate unit 314 of the lower cover 31. Further,tooth units 22 a formed of a plurality of ridges extending radially atequal angular intervals are formed on the lower surface of the secondbody unit 22, and the tooth units 22 a can be engaged with the toothunits 13 b of the first rotating body 13 if the second rotating body 20is moved downward.

Therefore, if the second rotating body 20 moves downward in thedirection of the axis L0 and the tooth units 13 b of the first rotatingbody 13 engage with the tooth units 22 a, the second rotating body 20rotates integrally with the first rotating body 13 in a coaxial state.As a result, the rotational driving force of the washing machine motor 5illustrated in FIG. 1 is transmitted to the washing tub 3 via the firstdriving force transmission path 1 a including the endless belt 12, thefirst rotating body 13, the second rotating body 20, and the couplingmember 15.

The clutch member 40 is arranged between the lower cover 31 and thesecond rotating body 20. The clutch member 40 has the annular unit 41and an engagement plate unit 42 protruding radially outward from onecircumferential direction of the annular unit 41, and an elongated hole43 extending in the radial direction is formed in the engagement plateunit 42. A drive pin 782 formed on an output member 78 of the actuator 7is fitted in the elongated hole 43. The annular unit 41 has the samesize as the ring-shaped bottom plate unit 314 of the lower cover 31 andthe ring-shaped first step unit 24 of the second rotating body 20, andthe first step unit 24 of the second rotating body 20 overlaps thebottom plate 314 of the first cover unit 311 of the lower cover 31 viathe annular unit 41 of the clutch member 40.

While on one hand, the upper surface 41 a of the annular unit 41 is aflat surface without irregularities, the first step unit 24 of thesecond rotating body 20 is also a flat surface without irregularities.Therefore, the upper surface 41 a of the annular unit 41 and the firststep unit 24 of the second rotating body 20 overlap each other in astate of surface contact. A guide mechanism 50 is formed between thelower surface 41 b of the annular unit 41 and the bottom plate unit 314of the lower cover 31. If the clutch member 40 rotates around the axisL0 passing through the center of the annular unit 41, the guidemechanism 50 causes the clutch member 40 to move to the connectionposition or the disconnection position described later. In the presentembodiment, if the clutch member 40 rotates around the axis L0 passingthrough the center of the annular unit 41, the clutch member 40 is movedin the direction of the axis L0 to move to the disconnection position orthe connection position. Therefore, the guide mechanism 50 formedbetween the lower surface 41 b of the annular unit 41 and thering-shaped bottom plate unit 314 of the lower cover 31 includes a cammechanism 51.

The cam mechanism 51 has a first projecting unit 56 protruding downwardso that an inclined surface 56 a faces one side L1 around the axis L0,on the lower surface 41 b of the annular unit 41 of the clutch member40, and the first projecting unit 56 has a flat lower end surface 56 borthogonal to the axis L0 in a portion adjacent to the other side L2around the axis L0 with respect to the inclined surface 56 a. In thepresent embodiment, the first projecting unit 56 is formed at threelocations in the circumferential direction, and portions of the lowersurface 41 b where the first projecting units 56 are not formed are flatsurfaces orthogonal to the axis L0.

In addition, the cam mechanism 51 has a second projecting unit 57protruding upward so that an inclined surface 57 a (the first camsurface) faces the other side L2 around the axis, on the upper surfaceof the bottom plate unit 314 of the lower cover 31, and the secondprojecting unit 57 has a flat upper end surface 57 b (the second camsurface) orthogonal to the axis L0 in a portion adjacent to one side L1around the axis L0 with respect to the inclined surface 57 a. In thepresent embodiment, the second projecting unit 57 is formed at threelocations in the circumferential direction, and portions of the uppersurface of the bottom plate unit 314 where the second projecting units57 are not formed are flat surfaces (the third cam surfaces) orthogonalto the axis L0.

Therefore, if the clutch member 40 is driven by the drive pin 782 of theactuator 7 and rotates to one side L1 around the axis L0, the firstprojecting unit 56 of the clutch member 40 runs on to the inclinedsurface 57 a of the second projecting unit 57 formed on the bottom plateunit 314 of the lower cover 31, and the first projecting unit 56overlaps the upper end surface 57 b of the second projecting unit 57. Asa result, the clutch member 40 pushes the second rotating body 20 upwardagainst the urging force of the compression coil spring 14 illustratedin FIG. 1. As a result, the engagement between the tooth units 22 a ofthe second rotating body 20 and the tooth units 13 b of the firstrotating body 13 is released, and the mechanical connection between thesecond rotating body 20 and the first rotating body 13 is released.Therefore, even if the first rotating body 13 rotates, the secondrotating body 20 does not rotate, and as a result, the pulsator 4illustrated in FIG. 1 rotates but the washing tub 3 does not rotate.

From this state, if the clutch member 40 is driven by the drive pin 782of the actuator 7 and rotates to the other side L2 around the axis L0,the first projecting unit 56 gets down the inclined surface 57 a of thesecond projecting unit 57 formed on the bottom plate unit 314 of thelower cover 31. As a result, the clutch member 40 and the secondrotating body 20 move downward by the urging force of the compressioncoil spring 14. For this reason, because the tooth units 22 a and thetooth units 13 b of the first rotating body 13 are engaged, the secondrotating body 20 and the first rotating body 13 are mechanicallyconnected. Accordingly, if the first rotating body 13 rotates, thesecond rotating body 20 also rotates, so that both the pulsator 4 andthe washing tub 3 illustrated in FIG. 1 rotate.

Configuration of Support Member 19

FIG. 5 is a perspective view of the state where the actuator 7 is fixedto the support member 19 illustrated in FIG. 2 as viewed from above. Thesupport member 19 illustrated in FIG. 2 and FIG. 5 is a member forsupporting the clutch device 10 at a predetermined position below thewashing tub 3, and is suspended from the main body frame 2 via a buffermember (not illustrated) together with the washing tub 3. The supportmember 19 is arranged between the upper cover 32 and the lower cover 31,and supports the clutch device 10.

The support member 19 includes a ring-shaped protruding unit 19 b thecenter portion of which is a through hole 19 a through which thesmall-diameter cylindrical unit 15 b of the coupling member 15 passes inthe direction of the axis L0. In the support member 19, theupper-surface side of the ring-shaped protruding unit 19 b is aring-shaped recessed unit 19 c, and in the recessed unit 19 c, aring-shaped bearing (not illustrated) that rotatably supports thewashing tub 3 from below via the coupling member 15 is arranged.

In the part below the flange units 19 d provided around the ring-shapedprotruding unit 19 b in the support member 19, the actuator 7 is fixedby two fastening members 98 and 99, described later, on the side of thering-shaped protruding unit 19 b.

Overall Configuration of Actuator 7

FIG. 6 is a perspective view of a clutch actuator unit 9 in which theactuator 7 and a sensor unit 8 illustrated in FIG. 2 and the like arecoupled to each other as viewed from the side opposite to the sensorunit 8. FIG. 7 is a perspective view of a state where the actuator 7 andthe sensor unit 8 are separated from the state illustrated in FIG. 6.FIG. 8 is a perspective view of the clutch actuator unit 9 illustratedin FIG. 6 as viewed from the sensor unit 8 side. FIG. 9 is a perspectiveview of a state where the actuator 7 and the sensor unit 8 are separatedfrom the state illustrated in FIG. 8. FIG. 10 is an exploded perspectiveview of a first case 70, a second case 80, and the like of the clutchactuator unit 9 illustrated in FIG. 6. FIG. 11 is an explodedperspective view of a drive mechanism 7 a, a sensor 8 a, and the like ofthe clutch actuator unit 9 illustrated in FIG. 6. It is noted that FIG.10 illustrates only the output member 78 and the connector 88 among themembers illustrated in FIG. 11.

As illustrated in FIGS. 6, 7, 8, and 9, the actuator 7 and the sensorunit 8 are coupled to each other to constitute the clutch actuator unit9, and as illustrated in FIG. 5, the actuator 7 and the sensor unit 8are integrally fixed below the support member 19.

The actuator 7 includes the drive mechanism 7 a (see FIG. 11) thatdrives the clutch member 40 illustrated in FIG. 3, and a first case 70in which the drive mechanism 7 a is housed.

As illustrated in FIG. 10, the first case 70 includes a plurality offirst members stacked in the up-down direction, and in the presentembodiment, the first case 70 includes a lowermost first member 71, anintermediate first member 72 arranged on the first member 71, and anuppermost first member 73 arranged on the intermediate first member 72.

In FIG. 10 and FIG. 11, a clutch motor 76 being the drive source and arotation transmission mechanism 77 that transmits the rotation of theclutch motor 76 are arranged between the first member 72 and the firstmember 73, and the output member 78 and a switch device 74 that detectsthe position of the output member 78 are arranged between the firstmember 71 and the first member 72.

The clutch motor 76 is a synchronous motor and can rotate only in onedirection. The clutch motor 76 is provided with a terminal block 765that holds two terminals 796. The rotation transmission mechanism 77includes a first gear 771 geared with a motor pinion (not illustrated),a second gear 772 geared with the first gear 771, a third gear 773geared with the second gear 772, a fourth gear 774 geared with the thirdgear 773, and a fifth gear 775 geared with the fourth gear 774. All ofthe first gear 771, the second gear 772, the third gear 773, and thefourth gear 774 are compound gears in which a small-diameter gear and alarge-diameter gear are integrally formed. The rotation transmissionmechanism 77 is a reduction gear mechanism that reduces the rotation ofthe clutch motor 76 and transmits the reduced rotation to the fifth gear775. A gear-shaped small-diameter unit 775 b of the fifth gear 775protrudes downward through a hole 72 p formed in the bottom wall of thefirst member 72.

In the second space demarcated by the first member 71 and the firstmember 72, the base-end side of the output member 78, a cam gear 79, andthe switch device 74 are arranged. The cam gear 79 has a disc unit 791and a cylindrical body unit 793 protruding upward from the disc unit791, and in a cylindrical unit 794 inside the body unit 793, a femalescrew that gears with the small-diameter unit 775 b of the fifth gear775 is formed. Therefore, the rotation of the clutch motor 76 istransmitted to the cam gear 79 via the fifth gear 775. In the cam gear79, the disc unit 791 has an eccentric pin 792 protruding downward fromthe disc unit 791 at a position separated from the rotation center axisof the cam gear 79.

The output member 78 has an extending unit 785 the leading end side ofwhich is protruding outside the first case 70, and a drive pin 782 thatprotrudes from the extending unit 785 in a direction perpendicular tothe direction in which the extending unit 785 extends. The leading endside of the output member 78 protrudes outside the first case 70 throughan opening unit 706 (see FIG. 6) provided in the first case 70, and isfitted in the elongated hole 43 of the clutch member40 described withreference to FIG. 3, FIG. 4, and the like.

An elongated hole 780 in which the eccentric pin 792 of the cam gear 79fits is formed in the extending unit 785 of the output member 78. Ashaft unit 781 is formed on the base-end side of the output member 78,and the shaft unit 781 is rotatably fitted inside a cylindrical unit(not illustrated) formed on the first member 72. Therefore, if theclutch motor 76 rotates and thus the cam gear 79 rotates, the outputmember 78 swings about the shaft unit 781 to cause the clutch member 40illustrated in FIG. 3 and FIG. 4 to rotate around the axis L0. If thecam gear 79 rotates further, the output member 78 swings in the oppositedirection about the shaft unit 781 to cause the clutch member 40 torotate in the opposite direction around the axis L0, thereby connectingand disconnecting the mechanical connection.

The switch device 74 includes a switch lever 740 rotatably supportedaround an axis La by a shaft unit (not illustrated) of the first member72, an urging member 746 for urging the switch lever 740 in onedirection around the axis La, and a push-type switch 747 the state ofwhich is switched by the displacement of the switch lever 740, and thepush-type switch 747 is mounted on a substrate 748. The switch lever 740has a first lever unit 741 and a second lever unit 742 extending indirections intersecting each other, and rotates around the axis La inconjunction with the output member 78. More specifically, the outerperipheral surface of the body unit 793 of the cam gear 79 is a camsurface 793 c, and the first lever unit 741 of the switch lever 740 iselastically brought in contact with the cam surface 793 c by the urgingforce of the urging member 746. Therefore, if the leading end unit ofthe first lever unit 741 is in contact with the small-diameter unit ofthe cam surface 793 c, the leading end unit of the second lever unit 742turns ON to push the switch 747. Then, if the cam gear 79 rotates fromthe ON state and the leading end unit of the first lever unit 741 comesin contact with the large-diameter unit of the cam surface 793 c, theswitch lever 740 rotates in the other direction around the axis La,because of which the leading end unit of the second lever unit 742 turnsOFF to be separated from the switch 747. Therefore, based on the outputfrom the switch 747, it is possible to monitor connection anddisconnection between the tooth units 22 a of the second rotating body20 and the tooth units 13 b of the first rotating body 13 illustrated inFIG. 3, etc.

Configuration of First Case 70

As illustrated in FIG. 6 through FIG. 10, the lower first member 71includes a bottom wall unit 710, and a side plate unit 711 protrudingupward from an edge of the bottom wall unit 710 toward the intermediatefirst member 72. The first member 72 includes a bottom wall unit 720facing the bottom wall unit 710 of the first member 71 at an upper side,and a side plate unit 721 protruding in the up-down direction from anedge of the bottom wall unit 720. The first member 73 includes a bottomwall unit 730 facing the bottom wall unit 720 of the first member 72 atan upper side, and a side plate unit 731 protruding downward from anedge of the bottom wall unit 730 toward the first member 72.

In the first case 70, the side plate unit 721 of the first member 71,the side plate unit 721 of the first member 72, and the side plate unit731 of the first member 73 are connected to each other to form the firstside surface 705 of the first case 70. More specifically, a plurality ofengagement protruding units 731 e and 731 f are formed on the outersurface of the side plate unit 731 of the first member 73. A pluralityof plate units 716 protruding upward toward each of the plurality ofengagement protruding units 731 e are formed in the first member 71, andan engagement hole 716 e in which the engagement protruding unit 731 eis fitted is formed in each of the plurality of plate units 716.Further, a plurality of plate units 726 protruding upward toward each ofthe plurality of engagement protruding units 731 f are formed in thefirst member 72, and an engagement hole 726 f in which the engagementprotruding unit 731 f is fitted is formed in each of the plurality ofplate units 726. Accordingly, it is possible to form the first case 70by coupling the three first members 71, 72, and 73, and the first sidesurface 705 being the side surface of the first case 70 is constitutedby the side plate unit 711 of the first member 71, the side plate unit721 of the first member 72, and the side plate unit 731 of the firstmember 73.

Configuration of Second Case 80

As illustrated in FIGS. 10 and 11, the sensor unit 8 includes a wiringboard 86, and the second case 80 that houses the wiring board 86, andthe sensor 8 a and a connector 88 are mounted on the wiring board 86.Accordingly, the sensor 8 a and the connector 88 are housed in thesecond case 80. The sensor 8 a includes a light emitting element 891mounted on a projecting unit 861 and a light receiving element 892mounted on a projecting unit 862 among the two projecting units 861 and862 protruding upward on the wiring board 86. The light emitting element891 and the light receiving element 892 face each other to constitute aphoto interrupter.

The second case 80 includes a plurality of second members stacked in theup-down direction, and in the present embodiment, the second case 80includes a second member 81 and a second member 82 arranged on thesecond member 81. In the second case 80, the lower second member 81 hasa bottom unit 810 that covers the connector 88 and the wiring board 86from below, and a side plate unit 811 protruding upward from the bottomunit 810. A plurality of engagement protruding units 811 e are formed onthe outer surface of the side plate unit 811. The upper second member 82has a cover unit 820 that covers the connector 88 and the wiring board86 from above, and a side plate unit 821 protruding downward from thecover unit 820. A plurality of plate units 826 protruding downwardtoward the plurality of engagement protruding units 811 e are formed onthe outer surface of the side plate unit 821, and an engagement hole 826e in which the engagement protruding unit 811 e is fitted is formed ineach of the plurality of plate units 826. Accordingly, it is possible toform the second case 80 by coupling the two second members 81 and 82,and the second side surface 805 being the side surface of the secondcase 80 is constituted by the side plate unit 811 of the second member81 and the side plate unit 821 of the second member 82.

Two hollow projecting units 828 and 829 protruding upward are formed inthe cover unit 820 of the second member 82. The projecting unit 861 ofthe wiring board 86 on which the light emitting element 891 is mountedis located inside the projecting unit 828, and the projecting unit 862of the wiring board 86 on which the light receiving element 892 ismounted is located inside the projecting unit 829. Therefore, asdescribed with reference to FIG. 5, if the sensor unit 8 is fixed to thesupport member 19 together with the actuator 7, the projecting units 828and 829 protrude upward from the opening unit 190 of the support member19, and the third body unit 23 of the second rotating body 20illustrated in FIG. 3 and FIG. 4 is located between the projecting units828 and 829. Thus, the sensor 8 a can detect the rotation of the washingtub 3 via the second rotating body 20. It is noted that a wiring member701 including a lead wire drawn out from the actuator 7 is electricallyconnected to the wiring board 86. Therefore, power is supplied to theactuator 7 and the signal of the sensor 8 a is output through theconnector 88. The driving of the actuator 7 is executed independently ofthe detection result of the rotation of the washing tub 3.

Waterproof Structure of First Case 70

FIG. 12 is a cross-sectional view illustrating the waterproof structureof the first case 70 and the second case 80 illustrated in FIG. 10 andthe like. In the present embodiment, among the plurality of firstmembers 71, 72, and 73 constituting the first case 70, the two firstmembers stacked in the up-down direction have a fitting structure inwhich the respective side plates overlap in both the up-down directionand the inner-outer direction. Further, among the two first members, theside plate of the first member located on the upper side overlaps theside plate of the first member located on the lower side from theoutside.

More specifically, as illustrated in FIGS. 10 and 12, in the side plateunit 711 of the lower first member 71, the end unit on the first member72 side (upper side) has a shape where a portion equivalent toapproximately ½ of the plate thickness has been cut out on the outside.For this reason, a thin plate portion 711 a is formed on the inner side,and a step unit 711 b is formed on the outer side at the end unit of theside plate unit 711. On the other hand, in the side plate unit 721 ofthe intermediate first member 72, the end unit on the first member 71side (lower side) has a shape where a portion equivalent toapproximately ½ of the plate thickness has been cut out on the inside.For this reason, a thin plate portion 721 a is formed on the outer side,and a step unit 721 b is formed on the inner side at the end unit of thelower side of the side plate unit 721. Therefore, if the first members71 and 72 are stacked in the up-down direction, the thin plate portion721 a of the side plate unit 721 of the first member 72 overlaps thethin plate portion 711 a of the side plate unit 711 of the first member71 from the outside, and at the same time, overlaps the step unit 711 bfrom above. Further, the thin plate portion 711 a of the side plate unit711 of the first member 71 overlaps the step unit 721 b of the sideplate unit 721 of the first member 72 from below.

Further, in the side plate unit 721 of the intermediate first member 72,a portion equivalent to approximately ½ of the plate thickness has beencut out on the outside of the end unit on the first member 73 side(upper side). For this reason, a thin plate portion 721 c is formed onthe inside and a step unit 721 d is formed on the outside of the upperend unit of the side plate unit 721. On the other hand, in the sideplate unit 731 of the upper first member 73, the end unit on the firstmember 72 side (lower side) has a shape where a portion equivalent toapproximately ½ of the plate thickness has been cut out on the inside.For this reason, a thin plate portion 731 c is formed on the outside anda step unit 731 d is formed on the inside of the lower end unit of theside plate unit 731. Therefore, if the first members 72 and 73 stackedin the up-down direction, the thin plate portion 731 c of the side plateunit 731 of the first member 73 overlaps the thin plate portion 721 c ofthe side plate unit 721 of the first member 72 from the outside, and atthe same time, overlaps the step unit 721 d from above. Further, thethin plate portion 721 c of the side plate unit 721 of the first member72 overlaps the step unit 731 d of the side plate unit 731 of the firstmember 73 from below.

Thus, in the first case 70, except for the opening unit 706 that causesthe leading end unit of the output member 78 to protrude outward,waterproofness is ensured between the side plate units 711 and 721 ofthe first members 71 and 72, and the side plate units 721 and 731 of thefirst members 72 and 73. Further, the side plate unit 721 of the firstmember 72 located above overlaps the side plate unit 711 of the firstmember 71 located below from the outside, and the side plate unit 731 ofthe first member 73 located above overlaps the side plate unit 721 ofthe first member 72 located below from the outside. Therefore, it ispossible to achieve excellent waterproofness against the water drippingfrom above.

Waterproof Structure of Second Case 80

In the second case 80, the two second members 81 and 82 stacked in theup-down direction have a fitting structure in which the respective sideplate units 811 and 821 overlap in both the up-down direction and theinner-outer direction. Further, among the two second members 81 and 82,the side plate unit 821 of the second member 82 located on the upperside overlaps the side plate unit 811 of the second member 81 located onthe lower side from the outside.

More specifically, in the side plate unit 811 of the second member 81,the end unit on the second member 82 side (upper side) has a shape wherea portion equivalent to approximately ½ of the plate thickness has beencut out on the outside. For this reason, a thin plate portion 811 a isformed on the inner side, and a step unit 811 b is formed on the outerside at the end unit of the upper side of the side plate unit 811. Onthe other hand, in the side plate unit 821 of the second member 82, theend unit on the second member 81 side (lower side) has a shape where aportion equivalent to approximately ½ of the plate thickness has beencut out on the inside. For this reason, a thin plate portion 821 a isformed on the outer side, and a step unit 821 b is formed on the innerside at the end unit of the lower side of the side plate unit 821.Therefore, if the second members 81 and 82 are stacked in the up-downdirection, the thin plate portion 821 a of the side plate unit 821 ofthe second member 82 overlaps the thin plate portion 811 a of the sideplate unit 811 of the second member 81 from the outside, and at the sametime, overlaps the step unit 811 b from above. Further, the thin plateportion 811 a of the side plate unit 811 of the second member 81overlaps the step unit 821 b of the side plate unit 821 of the secondmember 82 from below.

In this manner, in the second case 80, waterproofness between the sideplate units 811 and 821 of the second members 81 and 82 is ensuredthroughout the entire circumference. Further, the side plate unit 821 ofthe second member 82 located on the upper side overlaps the side plateunit 811 of the second member 81 located on the lower side from theoutside. Therefore, it is possible to achieve excellent waterproofnessagainst the water dripping from above.

Coupling Structure of First Case 70 and Second Case 80

To couple the actuator 7 and the sensor unit 8 to form the clutchactuator unit 9, a coupling unit 90 to couple the first case 70 and thesecond case 80 is provided outside the first case 70 and outside thesecond case 80. In the present embodiment, the coupling unit 90 isprovided in an overlapping portion of a first protruding unit 75protruding from the first side surface 705 of the first case 70, and asecond protruding unit 85 protruding from the second side surface 805 ofthe second case 80.

More specifically, in the first case 70, the first side surface 705 isformed by each side plate unit 711, 721, and 731 of the plurality offirst members 71, 72, and 73 stacked in the up-down direction, and thefirst protruding unit 75 is provided on the side plate unit of any oneof the first members 71, 72, and 73. In the second case 80, the secondside surface 805 is formed by each side plate unit 811 and 821 of theplurality of second members 81 and 82 stacked in the up-down direction,and the second protruding unit 85 is provided on the side plate unit ofany one of the second members 81 and 82. Further, among the plurality offirst members 71, 72, and 73, the first protruding unit 75 is providedin the side plate unit of the first member arranged on one of anuppermost side and the lowermost side, and among the plurality of secondmembers 81 and 82, the second protruding unit 85 is provided in the sideplate unit of the second member arranged on the other of the uppermostside and the lowermost side so as to overlap the first protruding unit75 from the other side.

In the present embodiment, among the plurality of first members 71, 72,and 73, the first protruding unit 75 is provided in the side plate unit731 of the first member 73 arranged at the uppermost side, and among theplurality of second members 81 and 82, the second protruding unit 85 isprovided in the side plate unit 811 of the second member 81 arranged atthe lowermost side so as to overlap the first protruding unit 75 fromthe other side (lower side).

Here, the first protruding unit 75 has a bottom plate unit 750protruding outward from the side plate unit 731 of the first member 73,and a side plate unit 751 protruding upward from the bottom plate unit750, and engagement protruding units 752 are formed on the outersurfaces of the two opposing side plate units 751. The second protrudingunit 85 has a bottom plate unit 850 protruding outward from the sideplate unit 811 of the second member 81 and overlapping the bottom plateunit 750 of the first protruding unit 75 from below. In the firstprotruding unit 75, the engagement protruding unit 752 is formed on anouter surface of the opposing side plate units 751. On the other hand,in the second protruding unit 85, a plate unit 851 protruding upwardfrom the two opposing sides of the bottom plate unit 850 toward theengagement protruding unit 752 and overlapping the side plate unit 731of the first protruding unit 75 is formed, and in the plate unit 851, anengagement hole 851 a into which the engagement protruding unit 752 ofthe first protruding unit 75 fits is formed. Therefore, as illustratedin FIGS. 6 to 9, if the bottom plate unit 850 of the second protrudingunit 85 is overlapped on the bottom plate unit 750 of the firstprotruding unit 75 from below, the engagement protruding unit 752 of thefirst protruding unit 75 elastically engages with the engagement hole851 a of the second protruding unit 85, and the first case 70 and thesecond case 80 are thus coupled.

Structure for Fixing Clutch Actuator Unit 9

In the present embodiment, a cylindrical unit 755 passing through in theup-down direction is formed in the bottom plate unit 750 of the firstprotruding unit 75, and a hole 855 that communicates with the hole 755 aof the cylindrical unit 755 is formed in the bottom plate unit 850 ofthe second protruding unit 85. Therefore, as illustrated in FIG. 5, tofix the clutch actuator unit 9 to the support member 19 of the washingmachine 1, the shaft unit of the fastening member 98 such as a bolt ispassed through the hole 855 and the hole 755 a of the cylindrical unit755, and then the fastening member 98 is fixed to the support member 19,and thereby the clutch actuator unit 9 can be fixed to the supportmember 19. Further, in the present embodiment, a cylindrical unit 735 isformed in the first member 73 used for the first case 70 of the actuator7. To fix the clutch actuator unit 9 to the support member 19 of thewashing machine 1, as illustrated in FIG. 5, the shaft unit of thefastening member 99 such as a bolt is passed through a hole 735 a of thecylindrical unit 735, and then the fastening member 99 is fixed into ahole 196 formed in the flange unit 19 d of the support member 19, andthereby the clutch actuator unit 9 can be fixed to the support member19.

It is noted that the first case 70 is provided with positioningprojecting units 736 and 737 protruding upward from the bottom wall unit730 of the first member 73. By fitting each of the positioningprojecting units 736 and 737 into the holes 197 and 198 formed in theflange units 19 d of the support member 19, the positioning of theclutch actuator unit 9 is performed.

Structure for Temporarily Fixing Fastening Member

(a) of FIG. 13 is a perspective view of the clutch actuator unit 9illustrated in FIG. 6 as viewed from below. (b) of FIG. 13 is across-sectional view illustrating a state in which the fastening member99 is temporarily fixed to the cylindrical unit 735, and is across-sectional view taken along a line A-A in (a) of FIG. 13. In FIG.13, FIG. 14, and FIG. 15, the up-down direction is the Z direction, oneside of the up-down direction Z is defined as a first side Z1, and theother side of the up-down direction Z is defined as a second side Z2.The first side Z1 is the lower side and the second side Z2 is the upperside.

As illustrated in FIG. 6, the cylindrical units 735 and 755 of the firstmember 73 include the holes 735 a and 755 a through which the fasteningmembers 98 and 99 for fixing the first case 70 and the second case 80 tothe support member 19 pass. A fastening member holding unit 760 thattemporarily fixes the fastening members 98 and 99 is provided on theinner peripheral surface of the holes 735 a and 755 a. As illustrated in(b) of FIG. 13, the fastening member holding unit 760 is a ribprotruding radially inward from the inner peripheral surface of the hole735 a. Because the fastening member holding unit 760 according to thepresent embodiment is a cylindrical rib formed on the entirecircumference on the inner peripheral surface of the hole 735 a, thefastening member 99 can be held on the entire circumference. Thefastening member 99 is held in the fastening member holding unit 760 byscrewing a leading end unit to the inner peripheral surface of thefastening member holding unit 760. A fastening member holding unit 760having the same shape as the fastening member holding unit 760illustrated in (b) of FIG. 13 is formed in the hole 755 a of thecylindrical unit 755 provided in the first protruding unit 75.Therefore, the fastening member 98 is held in the fastening memberholding unit 760 by screwing a leading end unit to the fastening memberholding unit 760.

After assembly, the clutch actuator unit 9 is shipped with the twofastening members 98 and 99 temporarily fixed to the fastening memberholding units 760 formed in the holes 735 a and 755 a, respectively.Then, in the assembly process of the washing machine 1, the clutchactuator unit 9 is fixed to the support member 19 using the fasteningmembers 98 and 99 held in the fastening member holding unit 760. In thepresent embodiment, as illustrated in (b) of FIG. 13, the fasteningmember 99 is inserted into the hole 735 a from the lower side Z1 andtemporarily fixed to the fastening member holding unit 760. Similarly,the fastening member 98 is inserted into the cylindrical unit 755 fromthe lower side Z1, and temporarily fixed to the fastening member holdingunit 760. Upon fixing the clutch actuator unit 9 to the support member19, as described above, the clutch actuator unit 9 is positioned withrespect to the support member 19 using the positioning projecting units736 and 737. Thereafter, the temporarily fixed fastening members 98 and99 are further screwed to the upper side Z2, whereby the leading endunits of the fastening members 98 and 99 are screwed and fixed to theflange unit 19 d of the support member 19 (see FIG. 5).

The cylindrical units 735 and 755 of the first member 73 extend in theup-down direction Z, and the holes 735 a and 755 a open on the firstside Z1 (lower side) and the second side Z2 (upper side). As illustratedin (b) of FIG. 13, the fastening member holding unit 760 is arranged inan intermediate portion in the up-down direction Z of the hole 735 a.That is, the fastening member holding unit 760 is located on the secondside Z2 as compared to the end unit 735 b on the first side Z1 of thehole 735 a, and is located on the first side Z1 as compared to the endunit 735 c on the second side Z2 of the hole 735 a. Similarly, thefastening member holding unit 760 provided in the hole 755 a is locatedon the second side Z2 as compared to the end unit on the first side Z1of the hole 755 a, and is located on the first side Z1 as compared tothe end unit on the second side Z2 of the hole 755 a. In this way, byarranging the fastening member holding unit 760 at a position away fromthe end unit of the holes 735 a and 755 a, it is possible to temporarilyfix the leading ends of the fastening members 98 and 99 so as not toproject out from the holes 735 a and 755 a.

The fastening member holding unit 760 includes a contact surface 761facing the first side Z1 or the second side Z2 in the up-down directionZ. As illustrated in (b) of FIG. 13, in the present embodiment, the endsurface of the second side Z2 of the fastening member holding unit 760(that is, the end surface facing upward) is the contact surface 761. Byproviding the contact surface 761 facing the up-down direction Z on thefastening member holding unit 760, the clutch actuator unit 9 can bepositioned in the up-down direction Z (that is, the axial direction ofthe holes 735 a and 755 a). For example, as illustrated in (b) of FIG.13, by bringing a leading end surface 102 of a positioning pin 101protruding from a positioning jig 100 in contact with the contactsurface 761, it is possible to position the clutch actuator unit 9 inthe up-down direction Z with respect to the positioning jig 100. Thepositioning jig 100 can be used to temporarily fix the fastening members98 and 99 to the clutch actuator unit 9. For example, the fasteningmember 99 is screwed until the leading end surface 99 a of the fasteningmember 99 comes in contact with the leading end surface 102 of thepositioning pin 101 abutting against the contact surface 761. Thereby,it is possible to temporarily fix the fastening member 99 at a positionwhere the leading end of the fastening member 99 does not protrude fromthe hole 735 a.

Positioning Structure by Fastening Member Holding Unit

FIG. 14 is a perspective view of the clutch actuator unit 9 and aninspection jig 200 illustrated in FIG. 6. FIG. 15 is a cross-sectionalview of the cylindrical unit 735 and the positioning pin 201, (a) ofFIG. 15 is a cross-sectional view illustrating a state before insertingthe positioning pin 201 into the cylindrical unit 735, and (b) of FIG.15 is a cross-sectional view illustrating a state in which the clutchactuator unit 9 is positioned using the positioning pin 201 and thepositioning unit 762.

The clutch actuator unit 9 is positioned on the inspection jig 200 toperform product inspection or the like after assembly. FIG. 14illustrates an example of the inspection jig 200. The inspection jig 200includes a jig main body 210 and two positioning pins 201 protrudingfrom the jig main body 210. In addition, the inspection jig 200 includesholes 203 and 204 into which the positioning projecting units 736 and737 formed on the first member 73 fit, and a hole 205 into which theprojecting units 828 and 829 of the sensor unit 8 fit. As illustrated inFIG. 14, the positioning pin 201 is inserted into the holes 735 a and755 a provided in the cylindrical units 735 and 755.

As illustrated in (a) of FIG. 15, the fastening member holding unit 760provided in the cylindrical unit 735 includes a positioning unit 762that comes into contact with the positioning pin 201. In the presentembodiment, the inner peripheral surface of the fastening member holdingunit 760 is the positioning unit 762. Before the fastening members 98and 99 are temporarily fixed, the positioning unit 762 has a cylindricalsurface. The inner diameter of the positioning unit 762 is substantiallyequal to the diameter of the positioning pin 201. Therefore, asillustrated in FIG. 15B, when the positioning pin 201 is inserted intothe inner peripheral side of the fastening member holding unit 760, thepositioning unit 762 and the outer peripheral surface of the positioningpin 201 come into contact with each other, and the clutch actuator unit9 is positioned with respect to the inspection jig 200.

When the fastening members 98 and 99 are temporarily fixed to thefastening member holding unit 760 after product inspection, thepositioning unit 762 is deformed by a male screw formed on the fasteningmembers 98 and 99. That is, the fastening members 98 and 99 aretemporarily fixed by screwing the fastening members 98 and 99 to thepositioning unit 762 being a cylindrical surface.

Main Effects of Present Embodiment

As described above, according to the present embodiment, because thecoupling unit 90 to couple the first case 70 of the actuator 7 and thesecond case 80 of the sensor unit 8 is provided outside the first case70 and outside the second case 80, it is possible to couple the firstcase 70 of the actuator 7 and the second case 80 of the sensor unit 8without causing a decline in the waterproof property of the first case70 and the second case 80. In particular, in the present embodiment, thecoupling unit 90 is provided in an overlapping portion of the firstprotruding unit 75 protruding from the first side surface 705 of thefirst case 70, and the second protruding unit 85 protruding from thesecond side surface 805 of the second case 80. Therefore, it is possibleto easily provide the coupling unit 90 between the first case 70 and thesecond case 80 outside the first case 70 and outside the second case 80.

Further, among the plurality of first members 71, 72, and 73constituting the first case 70, the first protruding unit 75 is providedon the uppermost first member 73, and among the plurality of secondmembers8l and 82 constituting the second case 80, the second protrudingunit 85 is provided on the lowermost second member 81 so as to overlapthe first protruding unit 75. Therefore, it is easy to realize astructure in which the first protruding unit 75 and the secondprotruding unit 85 overlap in the up-down direction.

Further, because holes 755 a and 855 through which the fastening members98 and 99 for fixing the first case 70 and the second case 80 to thewashing machine 1 pass are provided in the first protruding unit 75 andthe second protruding unit 85, respectively, it is possible to couplethe first case 70 and the second case 80, and also fix the first case 70and the second case 80 to the washing machine 1 using the firstprotruding unit 75 and the second protruding unit 85.

Further, in the present invention, holes 735 a and 755 a through whichthe fastening members 98 and 99 for fixing the first case 70 and thesecond case 80 to the washing machine 1 pass are provided in the firstmember 73 in which the first protruding unit 75 is provided, thefastening member holding unit 760 protruding radially inward is providedon the inner peripheral surface of the holes 735 a and 755 a provided inthe first member 73, or the inner peripheral surface of the holeprovided in the second member 81, and the fastening members 98 and 99are held in the fastening member holding unit 760. Therefore, it ispossible to temporarily fix the fastening members 98 and 99 to thefastening member holding unit 760 in advance and ship together with theclutch actuator unit 9. Thus, in a step of fixing the clutch actuatorunit 9 to the washing machine 1, it is not necessary to separatelysupply the fastening members 98 and 99. Further, it is possible toperform the fixing operation to the washing machine 1 from a state wherethe fastening members 98 and 99 are arranged in the fixing holes 735 aand 755 a in advance. This makes the fixing operation to the washingmachine 1 simple.

Further, in the present embodiment, the inner peripheral surface of thefastening member holding unit 760 is the positioning unit 762 abuttedagainst the positioning pin 201 provided on the inspection jig 200.Thus, the fastening member holding unit 760 can also be used as thepositioning unit 762 for positioning with respect to the inspection jig200, and as a result, there is no need to separately form thepositioning unit 762. Therefore, the configuration of the first member73 can be simplified.

It is noted that in the present embodiment, because the cylindricalunits 735 and 755 including the holes 735 a and 755 a through which thefastening members 98 and 99 for fixing the first case 70 and the secondcase 80 to the washing machine 1 pass are provided in the first member73 of the first case 70, the fastening member holding unit 760 and thepositioning unit 762 are provided in the holes 735 a and 755 a of thefirst member 73, but it is also possible to adopt a configuration inwhich cylindrical units including the holes through which the fasteningmembers 98 and 99 for fixing the first case 70 and the second case 80 tothe washing machine 1 pass are provided in the second member 81 of thesecond case 80. In this case, the hole of the second member can beprovided with a fastening member holding unit and a positioning unitthat protrude from the inner peripheral surface of the hole.

Other Embodiments

In the embodiment described above, among the plurality of first members71, 72, and 73 constituting the first case 70, the first protruding unit75 is provided in the uppermost first member 73, and among the pluralityof second members 81 and 82 constituting the second case 80, the secondprotruding unit 85 is provided in the lowermost second member 81,however, the first protruding unit 75 may be provided in the lowermostfirst member 71, and the second protruding unit 85 may be provided inthe uppermost second member 82.

In the embodiment described above, the engagement protruding unit 752 isprovided in the first protruding unit 75, and the plate unit 851 onwhich the engagement hole 851 a is formed is provided in the secondprotruding unit 85, however, the engagement protruding unit may beprovided in the second protruding unit 85, and the plate unit on whichthe engagement hole is formed may be provided in the first protrudingunit 75.

In the embodiment described above, the drive pin 782 of the outputmember 78 is fitted in the elongated hole 43 of the clutch member 40,but, for example, a structure in which the engagement pin provided inthe clutch member 40 is fitted in the elongated hole provided in theoutput member 78 may be adopted.

In the embodiment described above, the rotation of the clutch motor 76is transmitted to the output member 78 as the rotary motion of theeccentric pin 792 of the cam gear 79, however, the present invention maybe applied in a case where the rotary motion of the clutch motor 76 isconverted to linear motion and the linear motion is transmitted to theoutput member 78. In the embodiment described above, the actuator 7 isarranged so that the drive pin 782 faces upward (toward the washing tub3 side), but the actuator 7 may be arranged so that the drive pin 782faces downward (toward the side opposite to the washing tub 3).

What is claimed is:
 1. A clutch actuator unit, comprising: an actuatorcomprising a drive mechanism to drive a clutch member arranged in adriving force transmission path from a washing machine motor to awashing tub, and a first case in which the drive mechanism is housed;and a sensor unit comprising a sensor to detect rotation of the washingtub, and a second case in which the sensor is housed, wherein a couplingunit to couple the first case and the second case is provided outsidethe first case and outside the second case.
 2. The clutch actuator unitaccording to claim 1, wherein the coupling unit is provided in anoverlapping portion of a first protruding unit protruding from a firstside surface being a side surface of the first case, and a secondprotruding unit protruding toward the first case from a second sidesurface being a side surface of the second case.
 3. The clutch actuatorunit according to claim 2, wherein in the first case, the first sidesurface is formed by a plurality of first members stacked in an up-downdirection, and in the second case, the second side surface is formed bya plurality of second members stacked in the up-down direction, thefirst protruding unit is provided in any one of the plurality of firstmembers, and the second protruding unit is provided in any one of theplurality of second members.
 4. The clutch actuator unit according toclaim 3, wherein among the plurality of first members, the firstprotruding unit is provided in a first member arranged on one of anuppermost side and a lowermost side, and among the plurality of secondmembers, the second protruding unit is provided in a second memberarranged on the other of the uppermost side and the lowermost side so asto overlap the first protruding unit from the other side.
 5. The clutchactuator unit according to claim 4, wherein in each of the firstprotruding unit and the second protruding unit, a hole is providedthrough which a fastening member to fix the first case and the secondcase to a washing machine passes.
 6. The clutch actuator unit accordingto claim 4, wherein in the first member provided with the firstprotruding unit and the second member provided with the secondprotruding unit, a hole is provided through which a fastening member tofix the first case and the second case to a washing machine passes, inan inner peripheral surface of the hole provided in the first member, oran inner peripheral surface of the hole provided in the second member, afastening member holding unit protruding radially inward is provided,and the fastening member is held in the fastening member holding unit.7. The clutch actuator unit according to claim 6, wherein an innerperipheral surface of the fastening member holding unit is a positioningunit to come into contact with a positioning pin provided on a jig. 8.The clutch actuator unit according to claim 6, wherein the fasteningmember holding unit is formed on the entire circumference.
 9. The clutchactuator unit according to claim 6, wherein as compared to an end unitof the hole on a first side, the fastening member holding unit islocated on a second side opposite to the first side, and as compared toan end unit of the hole on the second side, the fastening member holdingunit is located on the first side.
 10. The clutch actuator unitaccording to claim 9, wherein the fastening member holding unitcomprises a contact surface facing the first side or the second side.11. The clutch actuator unit according to claim 3, wherein among theplurality of first members, the two first members stacked in the up-downdirection have a fitting structure in which side plates of the two firstmembers overlap in both the up-down direction and the inner-outerdirection, and among the plurality of second members, the two secondmembers stacked in the up-down direction have a fitting structure inwhich side plates of the two second members overlap in both the up-downdirection and the inner-outer direction.
 12. The clutch actuator unitaccording to claim 11, wherein among the two first members, the sideplate of the first member located on the upper side overlaps the sideplate of the first member located on the lower side from the outside,and among the two second members, the side plate of the second memberlocated on the upper side overlaps the side plate of the second memberlocated on the lower side from the outside.
 13. The clutch actuator unitaccording to claim 1, wherein the coupling unit comprises an engagementprotruding unit formed on one of the first case and the second case, andan engagement hole that is provided on the other of the first case andthe second case and in which the engagement protruding unit is fitted.14. A washing machine comprising the clutch actuator unit according toclaim 1, the washing machine comprising: the washing machine motor; thewashing tub; a pulsator arranged in the washing tub; and a driving forcetransmission mechanism to transmit a rotational driving force of thewashing machine motor to the washing machine tub and the pulsator,wherein the clutch actuator unit drives the clutch member to realize adisconnection state in which the rotational driving force is transmittedto the pulsator and is not transmitted to the washing tub, and aconnection state in which the rotational driving force is transmitted tothe washing tub and the pulsator.